CN110691759B - Method and apparatus for shaping glass sheets - Google Patents

Method and apparatus for shaping glass sheets Download PDF

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Publication number
CN110691759B
CN110691759B CN201880035219.1A CN201880035219A CN110691759B CN 110691759 B CN110691759 B CN 110691759B CN 201880035219 A CN201880035219 A CN 201880035219A CN 110691759 B CN110691759 B CN 110691759B
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Prior art keywords
glass sheet
mold
mould
forming
forming surface
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CN201880035219.1A
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CN110691759A (en
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S·C·史密斯
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Pilkington Group Ltd
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Pilkington Group Ltd
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    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B23/00—Re-forming shaped glass
    • C03B23/02—Re-forming glass sheets
    • C03B23/023—Re-forming glass sheets by bending
    • C03B23/03—Re-forming glass sheets by bending by press-bending between shaping moulds
    • C03B23/0305—Press-bending accelerated by applying mechanical forces, e.g. inertia, weights or local forces
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B23/00—Re-forming shaped glass
    • C03B23/02—Re-forming glass sheets
    • C03B23/023—Re-forming glass sheets by bending
    • C03B23/035—Re-forming glass sheets by bending using a gas cushion or by changing gas pressure, e.g. by applying vacuum or blowing for supporting the glass while bending
    • C03B23/0352—Re-forming glass sheets by bending using a gas cushion or by changing gas pressure, e.g. by applying vacuum or blowing for supporting the glass while bending by suction or blowing out for providing the deformation force to bend the glass sheet
    • C03B23/0355—Re-forming glass sheets by bending using a gas cushion or by changing gas pressure, e.g. by applying vacuum or blowing for supporting the glass while bending by suction or blowing out for providing the deformation force to bend the glass sheet by blowing without suction directly on the glass sheet
    • C—CHEMISTRY; METALLURGY
    • C03—GLASS; MINERAL OR SLAG WOOL
    • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
    • C03B35/00—Transporting of glass products during their manufacture, e.g. hot glass lenses, prisms
    • C03B35/14—Transporting hot glass sheets or ribbons, e.g. by heat-resistant conveyor belts or bands
    • C03B35/16—Transporting hot glass sheets or ribbons, e.g. by heat-resistant conveyor belts or bands by roller conveyors
    • C03B35/161—Transporting hot glass sheets or ribbons, e.g. by heat-resistant conveyor belts or bands by roller conveyors specially adapted for bent sheets or ribbons

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Re-Forming, After-Treatment, Cutting And Transporting Of Glass Products (AREA)

Abstract

A method of forming a glass sheet (50) is described, the method comprising: providing a forming support (15) for supporting the glass sheet; providing a press bending device comprising at least a first (17) and a second (19) mould part, each mould part being movable relative to the forming support; heating the glass plate; positioning the glass sheet on a forming support; moving at least one of the forming support and the press bending device towards the other to press the glass sheet in a first region of the glass sheet between the forming support and the first mold member (17); the second mold part (19) is moved relative to the first mold part to press the glass sheet in a second region of the glass sheet and the first mold part is moved relative to the forming support to further press the glass sheet between the first mold part and the second mold part in the first region of the glass sheet. An apparatus useful for carrying out the method is also described.

Description

Method and apparatus for shaping glass sheets
The present invention relates to a method of forming a glass sheet and an apparatus for forming a glass sheet.
Bending or shaping a flat glass sheet between a pair of shaping members having complementary shaping surfaces is well known in the art. Typically, a heat softened glass sheet is supported on an annular mold and bent between the annular mold and an upper integral full surface mold.
US2015/0000340A1 relates to an apparatus for forming glass comprising a lower mold, a stationary mold and an upper mold. Similar techniques in the display glass art include KR10-2015-0048450A and US2015/0274570A1.
JPS638229a involves shaping sheet glass into a hollow ultrathin glass article having a smooth surface and stable dimensions by securing a formable heated glass to a guide ring, pressing a plunger against the glass and forcing the glass into an open portion.
US5,401,286 relates to a flexible annular mold for shaping a heat softened glass sheet in which an inner ring is provided having a plurality of posts that help support the annular mold and maintain the mold in a generally planar configuration during initial lifting and shaping of the supported glass sheet.
In WO2005/033026A1 a press bending station is described, comprising an annular mould and a full surface mould. Holes selectively connected to a negative pressure source are placed in portions of the full-face mold, the locations of which holes are determined by the configuration of the ring mold when it is in contact with the heated glass sheet during press bending. The heated glass sheet is drawn through the holes by negative pressure toward the full-face mold to obtain its shape. The full-face mold may be covered with at least one fine mesh fabric, i.e., woven stainless steel.
In order to make certain complex curved glass shapes that may have particular uses as glazing panels in vehicle windows, it is sometimes not possible to bend the glass into the desired shape using integral press bending components. It has been found that for certain shapes, the use of integral press bending members causes the glass edge portions to buckle during the press bending operation, resulting in wrinkles in the glass edge that produce at least optical distortion.
In the prior art, this problem can be overcome by supporting the glass sheet on a lower annular mold and using an upper press bending member made of more than one moving member, as described in US5,122,177. In US5,122,177 it is described how the edges of a glass sheet to be bent are supported on a forming frame, the glass sheet is first clamped at its peripheral edges and then the central region of the glass sheet is pressed to the desired curvature.
A similar two-part mold is described in US2015/0007612 A1.
However, it has been found that when using such two-part press bending members as described in the prior art, for certain desired bent glass shapes, the press bending operation may cause very high stresses in the glass sheet during the bending operation, such that the glass sheet may fracture during forming.
The present invention aims to at least partially overcome the above problems.
Viewed from a first aspect, the invention therefore provides a method of shaping a glass sheet, the method comprising the steps of: (i) Providing a forming support for supporting a glass sheet; (ii) Providing a press bending device comprising at least two (first and second) mould parts, each of the first and second mould parts being movable relative to the forming support; (iii) heating the glass sheet; (iv) positioning the glass sheet on a forming support; (v) Moving at least one of the forming support and the press bending device toward the other to press the glass sheet in a first region of the glass sheet between the forming support and the first mold member; (vi) Moving the second mold member relative to the first mold member to press the glass sheet in a second region of the glass sheet, and (vii) moving the first mold member relative to the forming support to further press the glass sheet in the first region of the glass sheet between the first mold member and the forming support.
For the avoidance of doubt, the first mould part is movable relative to the forming support, the second mould part is movable relative to the forming support, and the first mould part is movable relative to the second mould part.
During step (v), the glass sheet is pressed between the forming support and the first mold member with sufficient force to allow the second mold member to press the glass sheet into a bend during step (vi), but in step (v) the first mold member is not in a final position relative to the forming support that provides the final desired curvature to the glass sheet in the first region of the glass sheet.
During step (vii), the glass sheet is pressed between the forming support and the first mold member to provide a final desired curvature to the glass sheet in a first region of the glass sheet.
It has been found that by only partially clamping the first region of the glass sheet during step (v), step (vii) is added to further press the glass sheet in the first region between the first mold part and the forming support, reducing the amount of glass breakage during forming.
Preferably, prior to step (v), the press bending device is configured such that the press bending device is not in contact with the glass sheet in the second region of the glass sheet prior to or during step (v).
Preferably, prior to or during step (v), the press bending device is in contact with the glass sheet in a second region of the glass sheet. In particular, it is preferred that the second mould part is in contact with the glass sheet in the second region of the glass sheet before or during step (v).
Preferably, during step (vii), the second mold part is also moved relative to the forming support to further press bend the glass sheet in the second region of the glass sheet. The second mold part may also be moved relative to the first mold part when the second mold part is moved relative to the forming support during step (vii).
Preferably, the movement of the first and second mould parts relative to the forming support is synchronised as the second mould part moves relative to the forming support during step (vii).
Preferably, the first region of the glass sheet is a peripheral region of the glass sheet. Preferably, the peripheral region extends around the entire periphery of the glass sheet.
Preferably, the second region of the glass sheet is a central region of the glass sheet.
Preferably, the first region of the glass sheet is a peripheral region of the glass sheet, in particular a peripheral region extending around the entire periphery of the glass sheet, and the second region of the glass sheet is a central region of the glass sheet, which central region of the glass sheet is inside the peripheral region of the glass sheet.
Preferably, the forming support comprises at least one rail for supporting the glass sheet around its peripheral region. Preferably, the forming support is an annular die for supporting the glass sheet in the peripheral region.
Preferably, during step (v), the glass sheet is pressed between the first mold part and the forming support in the peripheral region. When the forming support comprises at least one rail for supporting the glass sheet around its peripheral region, it is preferred that the glass sheet is pressed between the first mould part and the at least one forming rail of the forming support in the peripheral region of the glass sheet during step (v).
Preferably, during step (vi), the glass sheet is pressed in a central region of the glass sheet while the glass sheet is pressed between the first mold part and the forming support. When the forming support comprises at least one track for supporting the glass sheet around a peripheral region of the glass sheet, it is preferred that the glass sheet is pressed in a central region of the glass sheet while the glass sheet is pressed between the first mold part and the at least one forming track of the forming support during step (vi).
Preferably, the first mold part has a forming surface, and during step (v), the glass sheet faces the forming surface of the first mold part. Preferably, the first mold part has at least one opening in its forming surface, the at least one opening in the forming surface of the first mold part being in fluid communication with at least one vacuum source operable to provide at least one negative pressure region in a portion of the first region of the glass sheet after step (vii). The at least one vacuum source in fluid communication with the at least one opening in the forming surface of the first mold member can also be used to provide at least one negative pressure region at a portion of the first region of the glass sheet during at least one of steps (v), (vi) and (vii). The at least one opening in the forming surface of the first mold member can also be in fluid communication with a source of fluid, such as compressed air, such that after step (vii) at least one negative pressure region is provided in a portion of the first region of the glass sheet, and then fluid can be flowed through the at least one opening in the forming surface of the first mold member.
Preferably, the second mold part has a forming surface, and during step (vi), the glass sheet faces the forming surface of the second mold part. Preferably, the second mold part has at least one opening in its forming surface, the at least one opening in the forming surface of the second mold part being in fluid communication with at least one vacuum source operable to provide at least one negative pressure region in a portion of the second region of the glass sheet after step (vii). The at least one vacuum source in fluid communication with the at least one opening in the forming surface of the second mold member can also be used to provide at least one negative pressure region at a portion of the second region of the glass sheet during at least one of steps (v), (vi) and (vii). The at least one opening in the forming surface of the second mold member can also be in fluid communication with a source of fluid, such as compressed air, such that after step (vii) at least one negative pressure region is provided in a portion of the second region of the glass sheet, and then fluid can be flowed through the at least one opening in the forming surface of the second mold member.
Preferably, the press bending device is configured such that there is at least one (first) gap between the first and second mould parts. Preferably, the first gap is in fluid communication with at least one vacuum source operable to provide at least one region of negative pressure in a portion of the glass sheet opposite the first gap, the portion of the glass sheet opposite the first gap being between the first region and the second region of the glass sheet. The first gap can also be in fluid communication with a fluid source, such as compressed air, such that after step (vii) at least one negative pressure region is provided at a portion of the glass sheet opposite the first gap, and then fluid can be flowed through the first gap.
By applying negative pressure to one or more selected regions of the glass during bending of the glass, the glass bending process can be improved as described for example in WO2005000026A1 and WO2009002375 A1. Typically, after providing negative pressure to one or more selected regions of the glass during bending of the glass, after stopping the source of negative pressure, air (i.e., compressed air) is blown through openings in the forming surface in contact with the glass sheet to assist in removing the glass sheet from the forming surface.
Preferably, the first mold member has a forming surface with at least one opening therein, the second mold member has a forming surface with at least one opening therein, and at least one vacuum source is in fluid communication with the at least one opening in the forming surface of the first mold member and the at least one opening in the forming surface of the second mold member, wherein after step (vii), the at least one vacuum source is used to provide at least one negative pressure region in a portion of the first region of the glass sheet and at least one negative pressure region in a portion of the second region of the glass sheet.
Preferably, the first mold part has a mold part cover such that during step (v) the mold part of the first mold part covers between the first mold part and the glass sheet. Preferably, the mold part cover of the first mold part comprises a fabric, more preferably a breathable fabric. Preferably, the fabric comprises stainless steel, glass fibers, poly-p-phenylene terephthalamide fibers or mixtures thereof, polybenzoxazole (PBO) fibers containing graphite, and at least one of the various woven forms of these fibers. Typically, when the first mold part has a mold part cover, the mold part of the first mold part is covered between the first mold part and the glass sheet during steps (v), (vi) and (vii).
Preferably, the second mold part is provided with a mold part cover such that during step (v) the mold part of the second mold part covers between the second mold part and the glass sheet. Preferably, the mold part cover of the second mold part comprises a fabric, more preferably a breathable fabric. Preferably, the fabric comprises stainless steel, glass fibers, poly-p-phenylene terephthalamide fibers or mixtures thereof, polybenzoxazole (PBO) fibers containing graphite, and at least one of the various woven forms of these fibers. Typically, when the second mold part has a mold part cover, the mold part of the second mold part is covered between the second mold part and the glass sheet during steps (v), (vi) and (vii).
Preferably, the first and second mold parts each have a respective mold part cover, and wherein the mold part covers of the first and second mold parts are part of a single mold cover. During step (v), the single mold cap faces the glass sheet. Preferably, the single mold cover comprises a fabric, more preferably a breathable fabric. Preferably, the fabric comprises stainless steel, glass fibers, poly-p-phenylene terephthalamide fibers or mixtures thereof, polybenzoxazole (PBO) fibers containing graphite, and at least one of the various woven forms of these fibers. Typically, when the first mold part and the second mold part each have a respective mold part cover, during steps (v), (vi) and (vii), the respective mold part covers of the first mold part and the second mold part are between the first mold part and the glass sheet and between the second mold part and the glass sheet, respectively.
Preferably, during step (vi) the second mould part is moved from the first position to the second position, the first position of the second mould part being moved more than 2mm, preferably between 4mm and 20mm, more preferably between 5mm and 10mm, relative to the second position of the second mould part.
Preferably, during step (vi), the second mould is moved more than 2mm relative to the first mould part, preferably between 4mm and 20mm relative to the first mould part, more preferably between 5mm and 10mm relative to the first mould part.
Preferably, the first mould part has a forming surface facing the forming support and the second mould part has a forming surface facing the forming support, and prior to step (v) the press bending device is configured such that the forming surfaces of the first and second mould parts are displaced from each other by more than 2mm, preferably between 4mm and 20mm, more preferably between 5mm and 10 mm.
During step (iii), the glass sheet is heated to a temperature at which the glass sheet is suitably softened (i.e., has a suitably low viscosity) so as to be able to be shaped by press bending, in particular by press bending between a pair of complementary shaping members. Although selected areas of the glass sheet may be heated to different temperatures, it is preferred that the glass sheet be heated uniformly during step (iii).
Preferably, during step (iii), the glass sheet is heated to a temperature between 580 ℃ and 700 ℃.
Preferably, the glass sheet is heated prior to positioning the glass sheet on the forming support. However, the glass sheet may be positioned on the forming support and then heated. The glass sheet may be heated to a first temperature prior to positioning the glass sheet on the forming support and then heated to a second temperature on the forming support.
Preferably, the glass sheet is a sheet in a stack of glass sheets, in particular a nested (nested) pair.
Preferably, after step (vii), the bent glass sheet is thermally tempered by quenching the glass sheet with a jet of cooling fluid against at least one major surface of the glass sheet.
Preferably, after step (vii), laminating the bent glass sheet to another glass sheet using an interlayer structure comprising at least one sheet of interlayer material. Suitable interlayer materials include polyvinyl butyral, ethylene vinyl acetate copolymer, polyurethane, polycarbonate, polyvinyl chloride, or copolymers of ethylene and methacrylic acid.
Preferably, the glass sheet is supported on an annular mold having an upper shaping surface for supporting the glass sheet around at least a portion of the periphery of the glass sheet.
Preferably, the first mould part is an annular ring.
Preferably, the second mould part is a unitary mould which is at least partially disposed within the first mould part.
Preferably, the second mould part is arranged radially inside the first mould part.
Preferably, the press bending device comprises more than two mould parts.
Preferably, at least one of the first mould part, the second mould part and the forming support is provided with heating means.
Preferably, at least one of the first and second mould parts comprises at least one of ceramic, aluminium, stainless steel or iron, in particular cast iron.
Preferably, the forming support is vertically aligned with the press bending device.
The method according to the first aspect of the invention may be used to bend a flat glass sheet such that the bent glass sheet is curved in one or more directions. Preferably, the radius of curvature in at least one of the one or more directions is between 300mm and 20000mm, more preferably between 1000mm and 8000 mm. When the bent glass sheet is curved in two or more directions, it is preferable that the curvatures of two of the two or more directions are orthogonal to each other.
A suitable glass composition for a glass sheet is a soda lime silica glass composition.
Typical soda-lime-silica glass compositions are (by weight) 69 to 74% SiO 2 0 to 3% of Al 2 O 3 The method comprises the steps of carrying out a first treatment on the surface of the 10 to 16% of Na 2 O, 0 to 5% of K 2 O, 0 to 6% MgO, 5 to 14% CaO, 0 to 2% SO 3 0.005 to 2% Fe 2 O 3 . The glass may also contain other additives, such as fining aids, which are typically present in amounts of up to 2%. The soda-lime-silica glass composition may contain, for example, co 3 O 4 Other colorants of NiO and Se to impart a desired color to the glass when viewed in transmitted light. The transmitted glass color may be determined according to a recognized standard such as BS EN 410.
From a second aspect, the invention also provides an apparatus for shaping a glass sheet, the apparatus comprising: a press bending device comprising at least two (first and second) mold parts, each mold part having a forming surface, the press bending device having a first configuration, wherein the first mold part and the second mold part are configured such that the forming surface of the first mold part is aligned with the forming surface of the second mold part to provide the press bending device with a forming surface for pressing the glass sheet into a final shape when supported on a forming support, and a second configuration, wherein the forming surface of the first mold part is displaced relative to the forming surface of the second mold part, and the first mold part and the second mold part are movable relative to each other; the press bending apparatus further comprises control means to control the position of the first and second mould parts during the press bending operation, the control means being configured to control the position of the first and second mould parts relative to each other to perform at least one of steps (v), (vi) and (vii) of the method of the first aspect of the invention.
Preferably, the forming surface of the first mould part has at least one opening therein, and the at least one opening in the forming surface of the first mould part is in fluid communication with at least one negative pressure source, in particular at least one vacuum source. Preferably, after step (vii) in the method according to the first aspect of the invention, the control means further controls at least one negative pressure source to create at least one negative pressure region at the at least one opening in the forming surface of the first mould part. Preferably, during at least one of steps (v), (vi) and (vii) in the method according to the first aspect of the invention, the control means further controls at least one negative pressure source to create at least one negative pressure region at least one opening in the forming surface of the first mould part.
Preferably, the shaping surface of the second mould part has at least one opening therein, and the at least one opening in the shaping surface of the second mould part is in fluid communication with at least one source of negative pressure, in particular at least one vacuum source. Preferably, after step (vii) in the method according to the first aspect of the invention, the control device further controls at least one negative pressure source to create at least one negative pressure region at the at least one opening in the forming surface of the second mould. Preferably, during at least one of steps (v), (vi) and (vii) in the method according to the first aspect of the invention, the control means further controls at least one negative pressure source to create at least one negative pressure region at least one opening in the forming surface of the second mould.
Preferably, the press bending device is configured such that when the press bending device is in the first configuration, there is at least one (first) gap between the forming surface of the first mould part and the forming surface of the second mould part, more preferably wherein the first gap is in fluid communication with at least one source of negative pressure, in particular a vacuum source. Preferably, after step (vii) in the method according to the first aspect of the invention, the control device further controls the at least one negative pressure source to create at least one negative pressure region in the first gap. Preferably, during at least one of steps (v), (vi) and (vii) in the method according to the first aspect of the invention, the control device further controls the at least one negative pressure source to create at least one negative pressure region in the first gap.
Preferably, at least one of the first and second mould parts comprises at least one of ceramic, aluminium, stainless steel or iron, in particular cast iron.
Preferably, the first mould part is an annular ring.
Preferably, the second mould part is a unitary mould which is at least partially disposed within the first mould part.
Preferably, the second mould part is arranged radially inside the first mould part.
Preferably, the first mould part is an annular ring and the second mould part is arranged radially within the first mould part.
Preferably, the forming surface of the first mould part and/or the second mould part comprises a fabric, preferably a breathable fabric. Preferably, the fabric comprises stainless steel, glass fibers, poly-p-phenylene terephthalamide fibers or mixtures thereof, polybenzoxazole (PBO) fibers containing graphite, and at least one of the various woven forms of these fibers.
Preferably, at least one of the first and second mould parts is provided with heating means.
From a third aspect, the present invention provides an assembly comprising a press bending device according to the second aspect of the invention and a forming support for supporting a glass sheet thereon.
Preferably, the press bending device is arranged vertically with respect to the forming support.
Preferably, the press bending device is aligned with the forming support.
Preferably, in the first configuration, the forming support has an upper forming surface and the upper forming surface of the forming support is complementary to the forming surface of the press bending device.
Preferably, the forming support has a concave upper forming surface.
Preferably, the forming support is an annular mold having an upper forming surface for supporting the glass sheet around at least a portion of the periphery of the glass sheet.
Preferably, the assembly has at least three configurations: a first configuration of the assembly wherein the press bending device is in a first configuration and is spaced a first distance relative to the forming support; a second configuration of the assembly wherein the crimping device is in a second configuration; and a third configuration of the assembly, wherein the press bending device is in a third configuration wherein the first mold component is aligned with the forming surface of the second mold component, but the press bending component is spaced relative to the forming support a second distance that is different than the first distance. Preferably, the first configuration is the same as the second configuration.
In use, the assembly is preferably configured such that the buckling arrangement is disposed vertically relative to the support.
Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings (not to scale), in which:
FIG. 1 shows a schematic side view of a press bending station in a first configuration for bending a glass sheet;
FIG. 2 shows a schematic isometric view of a two-part press-bent component in a first configuration;
FIG. 3 shows a schematic isometric view of the two-part press-bent component of FIG. 2 in a second configuration;
FIG. 4 shows a schematic isometric view of the two-part press-bent component shown in FIG. 3 in spaced-apart relation to a lower support frame;
FIG. 5 shows a schematic view of an enlarged portion of the press bending station shown in FIG. 1;
FIG. 6 shows a schematic side view of the press bending station of FIG. 1 in a second configuration;
FIG. 7 shows a schematic side view of the press bending station of FIG. 1 in a third configuration, in which the first and second portions of the two-part press bending member have not been moved to a final bending position;
FIG. 8 shows a schematic side view of the press bending station of FIG. 1 in a fourth configuration in which the first and second portions of the two-part press bending member have been moved to a final bending position;
FIG. 9 shows a schematic side view of the press bending station of FIG. 1 in a fifth configuration, wherein the first and second portions of the two-part press bending member are in the same configuration as FIGS. 7 and 8, but both have been moved vertically and showing a curved glass sheet supported on the forming surface of the two-part press bending member;
FIG. 10 shows an enlarged schematic view of a portion of the press bending station shown in FIG. 1 with a glass sheet on a lower support;
FIG. 11 shows an enlarged schematic view of one portion of the press bending station shown in FIG. 10 after the two-part press bending member has been moved downward to contact the glass sheet at a central region of the glass sheet;
FIG. 12 shows an enlarged schematic view of a portion of the press bending station shown in FIG. 6;
FIG. 13 shows an enlarged schematic view of a portion of the press bending station shown in FIG. 7;
FIG. 14 shows an enlarged schematic view of a portion of the press bending station shown in FIG. 8;
FIG. 15 shows a schematic side view illustrating a glass bending line incorporating the press bending station shown in FIG. 1;
fig. 16 is a graph showing (for the first embodiment) the vertical position of the forming surfaces of the first and second portions of the two-part press-bent component as a function of time;
FIG. 17 is a graph showing the vertical position of the forming surfaces of the first and second portions of the two-part press-bent component as shown in FIG. 16 as a function of time, but with an expansion axis;
FIG. 18 is a graph showing (for the second embodiment) the vertical position of the forming surfaces of the first and second portions of the two-part press-bent component as a function of time;
FIG. 19 is a graph showing the vertical position of the forming surfaces of the first and second portions of the two-part press-bent component as shown in FIG. 18 as a function of time, but with an expansion axis;
FIG. 20 shows a schematic side view of a press bending station similar to that shown in FIG. 8, but with a single piece of fabric covering the first and second mold parts of the two-part press bending member; and is also provided with
Fig. 21 shows a schematic side view of a press bending station similar to that shown in fig. 8, but with a first fabric covering a first mold part of the two-part press bending part and a second, different fabric covering a second mold part of the two-part press bending part.
Fig. 1 shows a schematic side view showing a press bending station 1 for bending a glass sheet. The press bending station 1 comprises a lower part 3 and an upper part 5.
The lower portion 3 of the press bending station 1 comprises a forming support for supporting a glass sheet thereon. In this example, the forming support is a frame 7 having a base 9 with first and second uprights 11, 13 extending upwardly from the base 9. A lower support 15 in the form of an annular ring is mounted on the first and second uprights 11, 13. The lower support 15 has an upper forming surface 15a for supporting a glass sheet thereon, as is conventional in the art, i.e., a glass sheet (not shown) is supported about its peripheral region on the upper forming surface 15a of the lower support 15.
Generally, the lower portion 3 is referred to in the art as a curved frame or concave curved frame. Instead of a substantially annular support ring 15, a full contact support may be mounted on the ends of the uprights 11, 13.
In the example of fig. 1, the upper forming surface of the lower support 15 is concave. The lower support 15 may also be referred to as a "forming rail", or simply as a "rail".
Although only two uprights 11, 13 are shown in fig. 1, in practice there may be a plurality of uprights on which the lower support 15 is mounted.
The upper part 5 of the press bending station 1 comprises a press bending device comprising a two-part press bending part 6, which two-part press bending part 6 comprises a first mould part 17 and a second mould part 19. Examples of two-part moulds of this type are described in US5,122,177, WO2012166365A1 and US2015/0007612 A1.
With further reference to fig. 2, 3, 4 and 5, the first mold part 17 is an annular ring having a lower forming surface 21. The second mould part 19 is a unitary mould part fitted inside the central opening of the first mould part 17 such that the second mould part 19 is vertically movable relative to the first mould part 17. The second mould part 19 is arranged radially inside the first mould part 17.
The first mold member 17 has an outer peripheral wall 18a and an opposite inner peripheral wall 18b. The second mould part 19 has an outer peripheral wall 20. The outer peripheral wall 20 of the second mold part 19 faces the inner peripheral wall 18b of the first mold part 17 and is spaced apart from the inner peripheral wall 18b of the first mold part 17 by a gap 40. In the cross-sectional view of fig. 1, gap 40 is represented by two gaps 39 and 41.
The second mould part 19 has a lower forming surface 23. The forming surfaces 21, 23 are configured to provide a desired curvature of the glass sheet in those areas of the glass sheet that are to be contacted by the forming surfaces 21, 23 when the glass sheet is supported on the frame 7, i.e. on the upper forming surface 15a of the support 15, and when the first and second mold members are in some predetermined configuration.
As shown more clearly in fig. 4, one side of the lower support 15 is mounted on the uprights 11, 11' and 11' "and the opposite side is mounted on the uprights 13, 13' and 13". The uprights 11, 11', 11 ", 13', 13" extend upwards from the base 9, being connected at one end to the base 9 and at the opposite end to the lower support 15. Additional posts may be used. Reinforcing beams may also be used between the uprights.
With further reference to fig. 5, when the outer peripheral edge 20a of the second mold part 19 is aligned with the inner peripheral edge 18c of the first mold part 17, the two-part press curved part 6 has a forming surface corresponding to the desired final forming surface, as indicated by the dotted line 24. In this example, the forming surface of the two-part press-bending member 6 is a convex forming surface configured to be complementary to the upper forming surface 15a of the lower support 15. The desired final forming surface 24 is shown in phantom line 25 in a final desired position for forming the glass sheet supported on the upper forming surface 15a of the lower support 15 into a final desired shape.
Referring to fig. 1 and 5, the first mold part 17 is displaced relative to the second mold part 19 such that the forming surface of the two-part press bent part is not the desired final forming surface of the two-part press bent part. The outer peripheral edge 20a of the second mold part 19 is displaced from the inner peripheral edge 18c of the first mold part 17 by an amount 43.
The first mould part 17 is movable in a vertical direction (indicated by arrow 30) by means of linear actuators 31 and 33. The movements of the linear actuators 31, 33 are synchronized such that both sides of the first mould part 17 are moved upwards and downwards simultaneously.
The second mould part 19 is movable in the vertical direction 30 by means of a linear actuator 35.
Both the first and the second mould part 17, 19 are independently movable in a vertical direction relative to each other.
The linear actuators 31, 33 and 35 are mounted to a suitable frame 37 which is spatially fixed relative to the frame 7.
The movements of the linear actuators 31, 33 and 35 may be controlled by suitable control means such as a computer-based system (not shown).
In the configuration shown in fig. 1 (and fig. 5, which is an enlarged view of a portion of the left hand side of fig. 1), the forming surface 21 of the first mold part is displaced on one side by a vertical distance 27 from the final desired position indicated by the dotted line 25, and on the other side by a vertical distance 27' from the final desired position indicated by the dotted line 25. Preferably, distances 27 are the same as 27'.
The forming surface 23 of the second mold part 19 is displaced a vertical distance 29 from the final desired position indicated by the dotted line 25.
As discussed above, the press bending station 1 is shown in a first configuration in fig. 1, in which the forming surface 23 is displaced by an amount 43 relative to the forming surface 21. Due to the displacement 43, the two-part mould 6 is not configured to bend the glass sheet supported on the frame 7 into the final desired shape.
In fig. 1, two gaps 39, 41 between the inner circumferential wall 18b of the first mold part 17 and the outer circumferential wall 20 of the second mold part 19 are shown. These two gaps 39, 41 are part of a continuous gap 40 extending between the first mould part 17 and the second mould part 19, as illustrated in fig. 2 to 4. The gap 40 can be in fluid communication with a suitable vacuum source to assist in shaping the glass sheet by providing a negative pressure region in the gap. As can be seen, the gap 40 extends to the forming surface of the two-part press-bent part 6.
Fig. 6 shows a press bending station 1 in a different configuration than the one shown in fig. 1. In this second configuration, the glass sheet 50 has been positioned on the frame 7 and en route to the press bending process according to the invention. The glass pane 50 has a main surface 52 facing the two-part press-bending member 6 and an opposite main surface 54 facing the base 9 (and thus the frame 7 and the lower support 15). The major surface 54 of the glass sheet 50 is in contact with the upper forming surface 15a (not labeled in this figure, but see fig. 1) of the lower support 15.
Starting from the configuration shown in fig. 1, both the first and second mould parts 17 and 19 are moved downwards towards the frame 7 by energizing the respective linear actuators 31, 33 and 35. The downward movement of both the first and second mold parts 17, 19 is synchronized such that the first and second mold parts 17, 19 move downward without relative movement therebetween.
The downward movement of the first and second mould parts 17, 19 towards the frame 7 may be one or more stages, with or without relative movement between the first and second mould parts in each stage. In one example, in a first stage of downward movement, the downward speed of the first and second mold parts is a first speed u1, and in a second stage of downward movement, subsequent to the first stage of downward movement, the downward speed of the first and second mold parts is a second speed u2. Preferably u1 > u2, so that the first and second mould parts 17, 19 move faster in the first phase of the downward movement than in the second phase of the downward movement.
Referring to fig. 1 and 6, in the second configuration as shown in fig. 6, the forming surface 21 of the first mold member 17 has been in contact with the major surface 52 of the glass sheet 50 in the peripheral region of the glass sheet 50. Due to the specific configuration of the first and second mold parts 17, 19, the forming surface 23 of the second mold part 19 has also been in contact with the second major surface 52 of the glass sheet 50 in the central region of the glass sheet 50. The central region is inboard of the peripheral region of the glass sheet. The final desired position of the first and second mould parts 17, 19 has not been reached.
In fig. 7, the press bending station 1 is shown in another configuration than the one shown in fig. 1 and 6. Prior to this configuration, the press bending station 1 is in the configuration shown in fig. 6.
In this third configuration, shown in fig. 7, the second mold part 19 has been moved downwardly by energizing the linear actuator 35 so that the forming surface 23 of the second mold part 19 is further in contact with the major surface 52 of the glass sheet 50 in the central region of the glass sheet to press bend the central region of the glass sheet 50. In this example, the forming surface 23 is shown aligned with the forming surface 21 (see fig. 5 such that the displacement 43 is zero).
In this third configuration, the final desired position of the first and second mold parts 17, 19 is not reached, although the first and second mold parts 17, 19 are configured to provide the final desired forming surface to the two-part press-bent part 6. Referring to fig. 5, displacement 43 is zero, but both vertical distance 27 and vertical distance 29 are greater than zero because forming surface 21 and forming surface 23 have not yet reached the final position indicated by dashed line 25.
The final desired position of the first and second mold parts 17, 19 can be reached by moving the first and second mold parts 17, 19 further downward toward the frame 7 to further press bend the glass sheet 50 in the peripheral and central regions thereof. In this example, there is no relative movement between the first and second mold parts upon movement to the final desired positions of the first and second mold parts, such that during this further movement step the forming surface 23 remains aligned with the forming surface 21. This is further described with reference to fig. 8, although it is difficult to show different configurations due to the scale of the drawings.
In the fourth configuration shown in fig. 8, the forming surface 21 of the first mold member 17 is aligned with the forming surface 23 of the second mold member 19. Referring to fig. 5, the displacement 43 is zero. In this configuration, the two-part press bending member 6 has a pressing surface for pressing the glass sheet 50 supported on the frame 7 into a final desired shape, and press bending is configured such that the desired forming surface of the two-part press bending member 6 is also in a desired position. Referring to fig. 5, in this fourth configuration, both the forming surface 21 and the forming surface 23 are located on a dashed line 25. Starting from the configuration shown in fig. 7, both the first and second mold parts are moved simultaneously to the desired final position such that the forming surfaces 21, 23 remain aligned in moving from the configuration shown in fig. 7 to the configuration shown in fig. 8.
In the configuration shown in fig. 8, the gaps 39, 41 are in fluid communication with a vacuum source (not shown) to provide a negative pressure region at the major surface 52 of the glass sheet 50, at least in the vicinity of the glass sheet facing the gaps 39, 41.
The vacuum source may apply vacuum to the gaps 39, 41 for any desired time to improve bending of the glass sheet 50. The vacuum source is preferably applied to the gaps 39, 41 after the press bending station has reached the fourth configuration described above. The vacuum may be applied in stages, with a different level of vacuum applied in one stage than in another stage. The duration of the vacuum phase may be the same or different. The duration of the vacuum in the one or more vacuum stages may be between 0.05 and 5 seconds.
In fig. 9, the press bending station 1 is shown in another (fifth) configuration. In this fifth configuration, because the forming surfaces of the first and second mold members 17, 19 are aligned (with reference to fig. 5, displacement 43 is zero), the two-part press-bent member 6 is configured in substantially the same manner as shown in fig. 8. However, the construction of the press bending station 1 shown in fig. 9 differs from the construction of the press bending station 1 shown in fig. 8 in that the two-part mould 6 has been raised relative to the frame 7 by suitable actuation/energisation of the linear actuators 31, 33, 35. The first and second mould parts 17, 19 have been moved upwards towards the frame 37 at the same rate in the direction of arrow 30', i.e. the movement of the first and second mould parts 17, 19 upwards towards the frame 37 is synchronized, with no relative movement between the first and second mould parts.
By applying a vacuum at the gaps 39, 41 (and thus the gap 40, see fig. 2 to 4) to create a negative pressure region at the major surface 52 of the glass sheet opposite the gap, the bent glass sheet 50 is shown supported on the underside of the two-part press bending member 6.
In addition to applying vacuum in the gaps 39, 41, the forming surface 21 of the first mold member 17 can have openings therein in fluid communication with a vacuum source (which can be the same vacuum source as that used to provide vacuum in the gaps 39, 41). A vacuum source in fluid communication with the opening in the forming surface 21 may also be used to support the glass sheet 50 on the underside of the two-part press bending member 6.
Furthermore, in addition to applying vacuum to the gaps 39, 41 and/or openings in the forming surface 21 of the first mold member 17, the forming surface 23 of the second mold member 19 can also have openings therein in fluid communication with a vacuum source (which can be the same vacuum source as that used to provide vacuum in the gaps 39, 41). A vacuum source in fluid communication with the opening in the forming surface 23 may also be used to support the glass sheet 50 on the underside of the two-part press bending member 6.
The load ring 58 is shown disposed between the frame 7 (i.e., above the upper forming surface 15a of the lower support 15) and the two-part press-bending member 6. At a suitable time in the bending operation, the vacuum applied at the gaps 39, 41 (or gap 40) is terminated so that the bent glass sheet 50 is no longer supported on the underside of the two-part press bending part 6, but falls therefrom to be supported by the carrier ring 58. The gaps 39, 41 (or gaps 40) may also be in fluid communication with a suitable fluid source, such as compressed air, such that after the vacuum at the gaps 39, 41 ceases, fluid, i.e., compressed air, is flowed through the gaps 39, 41 toward the glass sheet 50 to assist in removing the curved glass sheet 50 from the forming surfaces 21, 23 of the respective first and second mold members 17, 19.
A suitable actuator (not shown) is provided to move the carrier ring 58 away from between the frame 7 and the two-part press bending member 6 in the direction of arrow 60. Thereafter, the bent glass sheet may be placed on a suitable conveyor (not shown) for subsequent annealing or tempering.
As discussed above, although not shown in the figures, the forming surface 21 of the first mold member 17 and/or the forming surface 23 of the second mold member 19 may have at least one opening therein in fluid communication with at least one negative pressure source, such as a vacuum source.
In addition to the negative pressure areas created in the gap 40, the or each opening in the forming surface 21 of the first mold member 17 and/or the or each opening in the forming surface 23 of the second mold member 19 may have additional negative pressure areas to enable improved shape control when bending the glass sheet.
If the forming surface 21 of the first mold member 17 has one or more openings therein for providing a vacuum (e.g., as described above with respect to gaps 39, 41), any number of the openings in the forming surface 21 may also be in fluid communication with a suitable fluid source, such as compressed air, to assist in removing the bent glass sheet from the forming surface 21 by flowing fluid through the openings toward the glass sheet after the vacuum is terminated.
Likewise, if the forming surface 23 of the second mold member 19 has one or more openings therein for providing a vacuum (e.g., as described above with respect to gaps 39, 41), any number of the openings in the forming surface 23 may also be in fluid communication with a suitable fluid source, such as compressed air, to assist in removing the bent glass sheet from the forming surface 23 by flowing fluid through the openings toward the glass sheet after the vacuum is terminated.
To further illustrate the sequence of movement of the first and second mold parts 17 and 19 during the forming process according to the present invention, the left hand portions of fig. 1 (except for glass sheet 50 on frame 7), 6, 7 and 8 have been enlarged and provided as additional figures. These enlarged portions of the above figures are shown in fig. 10, 12, 13 and 14, respectively. Additional fig. 11 is included to illustrate the instant when the forming surface 23 of the second mold member 19 contacts the glass sheet 50 in the central region of the glass sheet 50 before the forming surface 21 of the first mold member 17 contacts the glass sheet 50 in the peripheral region of the glass sheet 50 during the forming operation.
Referring to fig. 1 and 10, a glass sheet 50 is shown supported on the forming surface 15a of the lower support 15. The glass sheet has been suitably positioned on the forming surface 15a using methods known in the art. The glass sheet 50 has a first major surface 52 and an opposite second major surface 54. The second major surface 54 is in contact with the upper forming surface 15a of the lower support 15. The glass sheet has been heat softened and may sag slightly in its central region.
A portion (labeled 6') of the two-part press bending component 6 is shown above the glass sheet 50. The first mold part 17 has a forming surface 21 facing the first major surface 52 of the glass sheet 50 and the second mold part 19 has a forming surface 23 facing the first major surface 52 of the glass sheet 50.
As described above, the forming surfaces 21, 23 are offset from each other by the displacement 43 because the edges 18c and 20a are misaligned.
As shown in this figure, neither of the forming surfaces 21, 23 is in contact with the glass sheet 50.
In fig. 11, both the first and second mould parts 17, 19 have been moved downwards together so that there is no relative movement between them, i.e. starting from the configuration shown in fig. 10, both the first and second mould parts 17, 19 are moved at the same speed along arrow 30. In this way, the forming surfaces 21, 23 remain misaligned and the displacement 43 described above remains (in this case, the displacement 43 is the same as in fig. 10). In this configuration, the forming surface 23 is just in contact with the first major surface 52 of the glass sheet 50. However, because of the particular arrangement of the first and second mold members 17, 19 of the two-part press-bending member 6', the position of the first mold member 17 relative to the second mold member 19 is such that the forming surface 21 has not been in contact with the first major surface 52 of the glass sheet 50 (although the forming surface 23 has been in contact with the first major surface 52 of the glass sheet 50).
Different configurations of the first mold part 17 and the second mold part 19 of the two-part press-bending part 6' may be used, wherein the second mold part 19 is configured relative to the first mold part 17 such that the forming surface 21 of the first mold part 17 is in contact with the first major surface 52 of the glass sheet before the forming surface 23 of the second mold part 19 is in contact with the first major surface 52 of the glass sheet. In this alternative embodiment, the location of the second mold part is shown as an image as 19a with a shaped surface 23 a. It will be apparent that the first and second mold members can be configured such that their respective forming surfaces simultaneously contact the first major surface 52 of the glass sheet 50 as the first and second mold members move downwardly toward the frame at the same speed.
Fig. 12 is an enlarged view of a portion of the left hand side of fig. 6, showing the glass sheet 50 partially pressed in its peripheral region between the first forming member 17 and the lower support 15. Since both the first and second mold parts have continued to move downwardly (in the direction of arrow 30) at the same speed (when starting in the configuration shown in fig. 10 or 11), the glass sheet 50 is also slightly pressed in its central region by the second mold member 19. However, as described above, the forming surfaces of the first and second mold members still have a non-zero displacement 43.
Fig. 13 is an enlarged view of a portion of the left hand side of fig. 7, showing the two-part press bending member 6' after the configuration shown in fig. 12, wherein the first mold member 17 remains stationary relative to the lower support 15 and the second mold member 19 has been moved further downward (in the direction of arrow 30) to press bend the glass sheet 50 in the central region of the glass sheet 50. By being partially pressed between the first mould part 17 and the lower support 15, the glass sheet 50 is sufficiently held at its peripheral region. In this configuration there is no displacement (displacement 43 is zero) between the forming surfaces 21, 23 of the first and second mould parts 17, 19. Thus, the two-part press bending member 6' has the desired final forming surface, but the two-part press bending member is not in the final position to fully press bend the glass sheet 50 into the desired shape. This is shown in fig. 14 below.
Fig. 14 is an enlarged view of a portion of the left hand side of fig. 8, showing the two-part press-bent part 6' after the configuration shown in fig. 13, wherein both the first and second mould parts 17, 19 have been moved downwards simultaneously (in the direction of arrow 30), i.e. without relative movement between the first and second mould parts 17, 19. Again, there is no displacement between the forming surfaces of the first and second mold members (displacement 43 is zero). The two-part press bending member 6' has the desired final forming surface (because the displacement 43 is zero) and has been moved to a final position (see dashed line 25 in fig. 5) where the glass sheet 50 is completely press bent into the desired shape. After this final press bending step, a vacuum may be created in gap 39 (and gap 41, see FIG. 8) to hold glass sheet 50 on the underside of the two-part mold 6' and improve shape control of the bent glass sheet, as described above.
Fig. 15 shows a schematic cross-sectional view representing a portion of a glass bending line 70, the glass bending line 70 incorporating a press bending station 1 of the type shown in fig. 1, the operation of which is described with reference to fig. 1 to 14.
The glass bending line 70 includes a furnace 72, a press bend 74, which may or may not be heated, and an lehr 76.
The roller conveyor 78 extends through the furnace 72, the press bend 74, and the lehr 76 to define a conveyance path for the glass sheets 50. The roll conveyor includes a plurality of rolls 80 configured (in a spaced parallel relationship) to convey the glass sheet 50 in the direction of arrow 82. In this example, the glass sheet 50 is shown in contact with the rollers 80, but the glass sheet 50 may be positioned on a suitable carriage (not shown) that is in contact with the rollers 80. Alternatively to the rollers 80 or in addition to the rollers 80, an air floatation device may be used to transport the glass sheet in the direction of arrow 82.
In the heating furnace 72, the glass sheet 50 is heated to a temperature suitable for bending. The oven may incorporate any suitable heating means as desired, such as electrical heating, gas heating, convection heating and microwave heating, and combinations thereof.
Inside the press bending portion 74 is a press bending stage 1. When the glass sheet 50 is transferred between the frame 7 and the two-part press bending member 6, it is positioned on the frame 7 by being placed on the frame 7 for subsequent press bending, as already described with reference to fig. 1 to 14. Methods for transferring glass sheets from transfer rollers 80 to frame 7 are known in the art, for example, some transfer rollers may be configured as drop-down rollers, or a vacuum platen may be used to lift a heat softened glass sheet from the transfer rollers to rest on a suitably configured frame 7.
Referring to fig. 15 and 1, the two-part press bending part 6 is shown in electrical communication with a control device 84, such as a computer, for controlling the relative movement of the first and second mould parts 17, 19 of the two-part press bending part 6 by means of the linear actuators 31, 33, 35. The control device 84 can be in electrical communication with other portions of the glass bending line 70, such as the conveyor roll bed 78, to control the speed of the rolls 80 and/or actuators (not shown) that control the movement of the carrier ring 58.
The carrier ring 58 is shown between the press bend 74 and the lehr 76 and may be moved between the position shown in fig. 9 and the position shown in fig. 15 by a suitable actuator (not shown), i.e. by movement in the direction of arrow 60. The bent glass sheet supported by the carrier ring 58 moves from between the two-part press bending member 6 and the frame 7 (i.e., inside the press bend 74) to the outside of the press bend 74 where it can then be placed on a portion 78' of the roll transfer bed 78 for transfer into the lehr 76 for subsequent annealing, i.e., controlled cooling to ambient temperature.
Although the two-part press-bent part 6 is shown in the figures as having exposed forming surfaces 21 and 23 as previously described herein, in a preferred embodiment one or both of the first and second mould parts 17 and 19 may be provided with a protective cover to protect the forming surfaces of the mould parts from damage and wear. The lower support 15 may also be provided with such a protective cover to cover the upper forming surface 15a. When a cover is used, preferably the cover comprises a material made of, for example, stainless steel, fiberglass, polyphenylene terephthalamide fibers (e.g., kevlar TM ) Mixed Kevlar TM Materials, polybenzoxazole (PBO) fibers containing graphite (e.g. Zylon TM ) Or fabrics made from various woven forms of these fibers.
If a protective cover is used to cover each forming surface 21, 23, a single cover covering both forming surface 21 and forming surface 23 is preferably used.
If a protective cover is used that covers both forming surfaces 21 and 23, the protective cover should be flexible enough to allow the first and second mold members to move as previously described herein.
Furthermore, if a protective cover is used that covers both forming surfaces 21 and 23, it is preferred that the protective cover be sufficiently porous or breathable to allow a vacuum to be provided therethrough, such as through the gap 40 between the first and second mold parts, or any openings in the forming surfaces of the respective first and second mold parts as previously described.
A separate protective cover may be used for each of the forming surfaces 21, 23. This has the advantage that the gap between the first and second mould parts is not hindered by the material of the protective cover.
The downward movement of the first and second mould parts 17, 19 in the movement between the configurations shown in figures 1, 6, 7 and 8 (or figures 10 to 14) is illustrated in figures 16, 17 (for the first example) and in figures 18 and 19 (for the second example). Fig. 16 to 19 show the vertical position of the first 17 and second 19 mold parts relative to the final desired position of the forming surface of the parts indicated by line 25 in fig. 1 and 5.
In fig. 16 to 19, axis 90 is time in seconds and axis 92 is distance in mm.
In fig. 16 and 17, the dashed lines represent the vertical displacement of the forming surface 21 of the first mould part 17 relative to the final desired position of said forming surface 21. The solid line represents the vertical displacement of the forming surface 23 of the second mould part 19 relative to the final desired position of said forming surface 23. The final desired position of the forming surfaces 21, 23 (when they are aligned, see fig. 5, 7 and 13 and their associated description) is at a vertical displacement of-200 mm with respect to the reference datum of zero. At time=zero, the shaping surface 21 is at a reference datum of zero, and at time=zero, the shaping surface 23 is at +10mm relative to the reference datum of zero. That is, in the final desired position of the forming surface 21, the total vertical movement downward is 200mm, while for the forming surface 23 the total vertical movement downward is 210mm.
With reference to fig. 16 and 17, the relative movement of the first and second mold parts 17 and 19 in the first embodiment will be described.
At time t=0 (i.e. points a and a'), the two-part press bending die 6 is configured such that the forming surface 21 of the first die part 17 is displaced by 10mm with respect to the forming surface 23 of the second die part 19. Referring to fig. 5, distance 27 (and thus distance 27', see fig. 1) is 200mm, distance 29 is 210mm, and displacement 43 is 10mm.
After 0.5 seconds (at point B, B'), the press bending operation begins, both the first and second mold parts 17, 19 move vertically downward toward the glass sheet 50 supported on the frame 7, see, e.g., fig. 10. Both the first and second mould parts 17, 19 move downwards at the same speed (=v1) so that during this downwards movement phase there is no relative movement between the forming surfaces 21, 23 of the first and second mould parts 17, 19, i.e. at points B-C and B '-C', the movement of the first and second mould parts 17, 19 is synchronised and the displacement 43 remains fixed at 10mm.
After 1.2 seconds (at point C, C'), the rate of descent of first mold part 17 and second mold part 19 is reduced (to a rate v 2) as it approaches the surface of glass sheet 50. The simultaneous vertical downward movement of the first and second mould parts 17, 19 continues at a speed v2 until point D, D' is reached.
After 2.1 seconds (at point D), the second mold part 19 continues to move vertically downward at speed v 2. However, at point D' (which coincides in time with point D), the vertically downward movement of the first mold part 17 is stopped. The press bending station is in the configuration shown in fig. 6 (or fig. 12). At this point in time, the major surface 52 of the glass sheet 50 has been contacted by the forming surface 21 of the first mold part 17, such that the glass sheet 50 is partially pressed between the lower support 15 of the frame 7 and the first mold part 17.
During the next 0.2 seconds, the second mold part 19 continues to move downwardly at a speed v2 to press the glass sheet 50 in the central region of the glass sheet 50 while the glass sheet 50 remains partially pressed by the stationary first mold part 17. I.e. between points D 'and E', the first mould part 17 remains stationary with respect to the frame 7 to partially press the glass sheet in its peripheral region.
After 2.3 seconds (at point E '), the movement of the first mold part 17 is restarted at a selected downward speed (=v3) such that both the first mold part 17 and the second mold part 19 reach the final desired position simultaneously (at point F, F'). That is, the second mold part 19 continues to move vertically downward at a speed v2 between points E and F, while the first mold part moves vertically downward at a speed v3 between points E 'and F'.
The downward movement of the first mold part 17 between points E 'and F' further presses the peripheral edge region of the glass sheet between the upper shaping surface 15a of the lower support 15 and the shaping surface 21 of the first mold part. That is, in the peripheral region, the glass sheet is pressed further between the lower support 15 and the first mould part 17, while the glass sheet is bent further in the central region by the second mould part 19.
Obviously, as the second mould part 19 continues to move vertically downwards between points D and E, the spacing of the forming surfaces 21, 23 of the first and second mould parts 17, 19 decreases, as the first mould part 17 is stationary between points D 'and E' (which correspond to points D and E, respectively). Referring to fig. 5, the displacement 43 decreases between points D and E.
After 2.5 seconds (at point F, F'), both the first mold part 17 and the second mold part 19 have reached the final desired position and the glass sheet 50 is press bent into the final desired shape. The press bending station is in the configuration shown in fig. 8 or 14. At point F, F', the shaped surface of the two-part curved part 6 has the final desired curvature.
In this particular example of a method according to the first aspect of the invention (as illustrated in fig. 16 and 17), the initial spacing (displacement 43) of the forming surfaces of the first press and the second press is 10mm. The first mould part 17 is moved vertically downwards to a position such that the position of the forming surface 21 is 2mm from the final position of the forming surface 21. The forming surfaces 21, 23 are then moved as described above to reach the final position indicated by point F, F simultaneously, which is two seconds after the initial vertical downward movement of both the first and second mold parts 17, 19 has begun, i.e. two seconds after point B, B'.
By stopping the first mold part 17 at point D ' and then restarting the downward movement of the first mold part at point E ', it is found that further downward movement of the first mold part 17 moves the forming surface 21 to the final position while the forming surface 23 of the second mold part 19 reaches the final position, i.e. at point F, F ', the transient stresses generated in the glass sheet 50 during the press bending operation are reduced compared to when the first mold part 17 is moved to the final position without prior stopping. That is, in the event that the first mold part does not stop at point D', but continues at speed v2 until the forming surface 21 of the first mold part 17 is in the final desired position (i.e., -200mm from zero reference), there is more glass breakage during the press bending operation.
Another test was performed using the changed downward movement of the first and second mold parts 17 and 19.
This second example is described with reference to fig. 18 and 19. In fig. 18 and 19, the dashed lines represent the vertical displacement of the forming surface 21 of the first mould part 17 relative to the final desired position of said forming surface 21. The solid line represents the vertical displacement of the forming surface 23 of the second mould part 19 relative to the final desired position of said forming surface 23. The final desired position of the forming surfaces 21, 23 (when they are aligned, see fig. 5, 7 and 13 and the associated description) is-200 mm of vertical displacement with respect to the zero reference datum. The forming surface 21 is at a zero reference point at time=zero and the forming surface 23 is at +10mm relative to the zero reference point at time=zero. That is, in the final desired position of the forming surface 21, the total downward movement is 200mm, while for the forming surface 23 the total downward movement is 210mm.
In fig. 18 and 19, up to point D, D' (at 2.1 seconds), the movement of the first and second mold parts 17 and 19 in this second example is the same as in the first example (as illustrated in fig. 16 and 17). That is, between points B and C (and B 'and C'), both the first and second mold parts 17 and 19 move vertically downward at a speed of v1 (displacement 43 is fixed at 10 mm), and between points C and D (and C 'and D'), both the first and second mold parts 17 and 19 move vertically downward at a speed of v2 (again, displacement 43 is fixed at 10 mm).
In this second example, at point D, the second mould part 19 continues to move vertically downwards at the same speed v2 until the final position is reached at point F. The second mould part 19 in this second example is moved downwards in the same way as in the first example described in relation to figures 16 and 17.
As in the first example, in the second example, the downward movement of the first mold part stops when it reaches point D (after 2.1 seconds). However, contrary to the first example, the first mold part remains stationary until the forming surface 21 of the first mold part 17 and the forming surface 23 of the second mold part are aligned (at point G, G'). Referring to fig. 5, at point G, G', the displacement 43 is zero and the forming surfaces 21, 23 are aligned. The two-part press-bent part 6 has a final desired forming surface (indicated by dotted line 24 in fig. 5), but the final desired forming surface is not in the desired final position (indicated by dashed line 25 in fig. 5).
At this point, when the displacement 43 is zero (which is about 2.43 seconds), the downward movement of the first mold part 17 resumes at point G' to move the forming surface 21 of the first mold part and the forming surface 23 of the second mold part to the final desired position.
Between points G 'and F', the movements of the first and second mould parts 17, 19 are again synchronised such that there is no relative vertical movement between the two forming surfaces 21, 23. The first and second mould parts 17, 19 move vertically downwards at the same speed (=v2) until the final position F, F' is reached, which is at a vertical distance of-200 mm from the reference datum of zero. The forming surfaces 21, 23 are aligned and the displacement 43 is zero.
The press bending device is then also in the configuration shown in fig. 8 (and in fig. 14), but the relative movement between the first and second mould parts during the press bending operation is different compared to the first example of the method (as described above with reference to fig. 16 and 17). The second example described above is illustrated in fig. 10 to 14.
Such a method according to the invention is particularly useful for bending an initially flat glass sheet to a final curvature for use as a bent glass sheet for an automobile, for example as a layer in a windscreen, or as a sheet for a side, rear or roof window, i.e. a roof window. Two such bent glass sheets may be used in a vehicle windshield and are joined together by at least one layer of an adhesive interlayer material such as polyvinyl butyral (PVB).
Fig. 20 shows a schematic side view of another press bending station 1', which press bending station 1' is substantially identical to the press bending station 1 described with reference to fig. 1 to 8, except that there is a single piece of fabric 16 covering the first 17 and second 19 mould parts of the two-part press bending part 6.
The press bending station 1' is shown in substantially the same construction as the press bending station 1 in fig. 8. However, because the first and second mold parts are covered by a single piece of fabric 16, the forming surface of the first mold part 17 is covered by the fabric 16 such that the fabric 16 is in direct contact with the major surface 52 of the glass sheet 50. In this way, the forming surface 21 of the first mold member 17 and the forming surface 23 of the second mold member 19 are in indirect contact with the major surface 52 of the glass sheet 50.
Preferably, the fabric 16 is a breathable fabric. Preferably, the fabric 16 comprises stainless steel, fiberglass, poly-p-phenylene terephthalamide fibers or mixtures thereof, polybenzoxazole (PBO) fibers containing graphite, and at least one of the various braided forms of these fibers.
Fig. 21 shows a schematic side view of another press bending station 1 ", which press bending station 1" is substantially identical to the press bending station 1 described with reference to fig. 1 to 8, except that there is a first fabric 16 'covering the first mould part 17 and a second fabric 16 "covering the second mould part 19, i.e. the fabric 16' covers the forming surface 21 of the first mould part 17 and the fabric 16" covers the forming surface 23 of the second mould part 19. To accommodate both fabric covers, a second mold part 19 'is provided with a slightly smaller forming surface to accommodate the fabric extending to the outer 18a and inner 18b peripheral walls of the first mold part 17 and the outer peripheral wall 20 of the second mold part 19'. Thus, the gaps 39', 41' are slightly wider than the gaps 39, 41 of FIG. 1. Moreover, because of the use of two pieces of fabric 16', 16 ", the gaps 39' and 41 'are not impeded by the fabric near the forming surface of the two-part press-bending member 106 (labeled 106 because the second mold member 19' is different from the second mold member 19 of the two-part press-bending member 6). The use of two or more fabrics also provides the advantage that only selected areas of the fabric can be replaced when the fabric is worn due to continued use in bending the glass sheet. When one piece of fabric is used, if the fabric wears out, the entire piece of fabric needs to be replaced, and when at least the first and second fabrics are used, only one piece of fabric may be replaced as needed.
The press bending station 1 "is shown in substantially the same configuration as the press bending station 1 in fig. 8. However, because the first mold part 17 is covered by the fabric 16', the second mold part 19' is covered by the fabric 16 ". Fabrics 16' and 16 "are in direct contact with first major surface 52 of glass sheet 50. In this way, the forming surface 21 of the first mold member 17 and the forming surface 23 of the second mold member 19 are in indirect contact with the first major surface 52 of the glass sheet 50 via the fabrics 16' and 16 ", respectively.
Preferably, at least one of the fabrics 16', 16 "is a breathable fabric. Preferably, the fabric 16' and/or 16 "comprises stainless steel, glass fibers, poly-p-phenylene terephthalamide fibers or mixtures thereof, graphite-containing Polybenzoxazole (PBO) fibers, and at least one of the various braided forms of these fibers.
It has been found that when using the method of shaping a glass sheet according to the invention, and when improving wrinkles in the peripheral region of a bent glass sheet (as compared to using a single integral upper press bending part), the risk of glass breakage during the shaping operation, i.e. the press bending operation, is reduced.
Although the examples provided herein relate to only two-part press bending members, the press bending device may comprise a press bending member having three or more independently movable mold members, e.g., two opposing lateral peripheral regions of the glass sheet may be pressed during step (v), and a central region of the glass sheet between the two opposing lateral peripheral regions of the glass sheet may be pressed during step (vi).

Claims (51)

1. A method of forming a glass sheet comprising the steps of:
(i) Providing a forming support for supporting a glass sheet;
(ii) Providing a press bending device comprising at least a first and a second mould part, each of the first and second mould parts being movable relative to the forming support;
(iii) Heating the glass plate;
(iv) Positioning the glass sheet on a forming support;
(v) Moving at least one of a forming support and a press bending device toward the other to press the glass sheet in a first region of the glass sheet between the forming support and the first mold member;
(vi) Moving the second mold member relative to the first mold member to press the glass sheet in a second region of the glass sheet, and
(vii) Moving the first mold part relative to the forming support to further press the glass sheet between the first mold part and the forming support in a first region of the glass sheet,
wherein the first region of the glass sheet is a peripheral region of the glass sheet, and wherein the second region of the glass sheet is a central region of the glass sheet.
2. The method of claim 1, wherein the press bending device is in contact with the glass sheet at a second region of the glass sheet prior to or during step (v).
3. A method according to claim 1 or claim 2, wherein during step (vii) the second mould part is moved relative to the forming support glass sheet to further press bend the glass sheet in a second region of the glass sheet.
4. A method according to claim 3, wherein during step (vii) the second mould part is also moved relative to the first mould part.
5. A method according to claim 3, wherein during step (vii) the movement of the first and second mould parts relative to the forming support is synchronised.
6. A method according to claim 1 or 2, wherein the forming support comprises at least one track for supporting the glass sheet around a peripheral region of the glass sheet.
7. The method of claim 6, wherein the forming support is an annular die for supporting the glass sheet in a peripheral region.
8. The method of claim 6, wherein during step (v), the glass sheet is pressed between the first mold component and the forming support in a peripheral region.
9. A method according to claim 1 or 2, wherein during step (vi) the glass sheet is pressed at a central region of the glass sheet while the glass sheet is pressed between the first mould part and the forming support.
10. A method according to claim 1 or 2, wherein the first mould part has a forming surface and during step (v) the glass sheet faces the forming surface of the first mould part.
11. A method according to claim 1 or 2, wherein the first mould part has at least one opening in its forming surface, the at least one opening in the forming surface of the first mould part being in fluid communication with at least one vacuum source operable to provide at least one negative pressure region in a portion of the first region of the glass sheet after step (vii).
12. A method according to claim 1 or 2, wherein at least one opening in the forming surface of the first mould part is in fluid communication with at least one fluid source such that after step (vii) fluid can be caused to flow through at least one opening in the forming surface of the first mould part.
13. A method according to claim 1 or 2, wherein the second mould part has a forming surface and during step (vi) the glass sheet faces the forming surface of the second mould part.
14. A method according to claim 1 or 2, wherein the second mould part has at least one opening in its forming surface, the at least one opening in the forming surface of the second mould part being in fluid communication with at least one vacuum source operable to provide at least one region of negative pressure in a portion of the second region of the glass sheet after step (vii).
15. A method according to claim 1 or 2, wherein at least one opening in the forming surface of the second mould part is in fluid communication with at least one fluid source such that after step (vii) fluid can be caused to flow through at least one opening in the forming surface of the first mould part.
16. The method of claim 1 or 2, wherein the press bending device is configured such that there is at least a first gap between the first and second mold parts.
17. The method of claim 16, wherein the first gap is in fluid communication with at least one vacuum source operable to provide at least one negative pressure region at a portion of the glass sheet opposite the first gap, the portion of the glass sheet opposite the first gap being between a first region and a second region of the glass sheet.
18. The method of claim 16, wherein the first gap is in fluid communication with at least one fluid source such that after step (vii) fluid can be flowed through the first gap.
19. A method according to claim 1 or 2, wherein the first mould part has a mould part cover such that during step (v) the mould part of the first mould part covers between the first mould part and the glass sheet.
20. The method of claim 19, wherein the mold part cover of the first mold part comprises a fabric.
21. The method of claim 20, wherein the fabric is a breathable fabric.
22. The method of claim 20, wherein the fabric comprises a fabric of stainless steel, glass fibers, poly-p-phenylene terephthalamide fibers, or mixtures thereof, graphite-containing Polybenzoxazole (PBO) fibers, and at least one of the various braided forms of these fibers.
23. The method of claim 1 or 2, wherein the second mold part has a mold part cover such that during step (vi) the mold part of the second mold part covers between the second mold part and the glass sheet.
24. The method of claim 23, wherein the mold part cover of the second mold part comprises a fabric.
25. The method of claim 24, wherein the fabric is a breathable fabric.
26. The method of claim 24, wherein the fabric comprises a fabric of stainless steel, glass fibers, poly-p-phenylene terephthalamide fibers, or mixtures thereof, graphite-containing Polybenzoxazole (PBO) fibers, and at least one of the various braided forms of these fibers.
27. The method of claim 19, wherein the first and second mold parts each have a respective mold part cover, and wherein the mold part covers of the first and second mold parts are part of a single mold cover.
28. The method of claim 27, wherein the single mold cap comprises a fabric.
29. The method of claim 28, wherein the fabric is a breathable fabric.
30. The method of claim 28 or 29, wherein the fabric comprises stainless steel, glass fibers, poly-p-phenylene terephthalamide fibers or mixtures thereof, graphite-containing Polybenzoxazole (PBO) fibers, and at least one of the various braided forms of these fibers.
31. A method according to claim 1 or 2, wherein during step (vi) the second mould part is moved more than 2mm relative to the first mould part.
32. The method of claim 31, wherein during step (vi), the second mold part is moved 4mm to 20mm relative to the first mold part.
33. The method of claim 31, wherein during step (vi), the second mold part is moved 5mm to 10mm relative to the first mold part.
34. A method according to claim 1 or 2, wherein the first mould part has a forming surface facing the forming support and the second mould part has a forming surface facing the forming support, and prior to step (v) the press bending device is configured such that the forming surfaces of the first and second mould parts are displaced from each other by more than 2mm.
35. The method of claim 34, wherein prior to step (v), the press bending device is configured to displace the forming surfaces of the first and second mold members from each other by 4mm to 20mm.
36. The method of claim 34, wherein prior to step (v), the press bending device is configured to displace the forming surfaces of the first and second mold members from 5mm to 10mm from each other.
37. A method according to claim 1 or 2, wherein during step (iii) the glass sheet is heated to a temperature suitable for press bending.
38. A method according to claim 1 or 2, wherein during step (iii) the glass sheet is heated to a temperature between 580 ℃ and 700 ℃.
39. The method of claim 1 or 2, wherein the glass sheet is a sheet in a stack of glass sheets.
40. The method of claim 39, wherein the glass sheets are a nested pair.
41. The method of claim 1 or 2, wherein step (iv) is performed before step (iii).
42. A method according to claim 1 or 2, wherein during step (iii) the glass sheet is heated on the forming support.
43. A method according to claim 1 or 2, wherein after step (vii), the bent glass sheet is thermally tempered by quenching the glass sheet with a jet of cooling fluid against at least one major surface of the glass sheet.
44. A method according to claim 43, wherein after step (vii), the curved glass sheet is laminated to another glass sheet using an interlayer structure comprising at least one sheet of interlayer material.
45. The method of claim 44, wherein the interlayer material is polyvinyl butyral, ethylene vinyl acetate copolymer, polyurethane, polycarbonate, polyvinyl chloride, or a copolymer of ethylene and methacrylic acid.
46. A method according to claim 1 or 2, wherein the first mould part is an annular ring.
47. The method according to claim 1 or 2, wherein the second mould part is a unitary mould which is at least partially arranged within the first mould part, and/or wherein the second mould part is arranged radially within the first mould part.
48. The method according to claim 1 or 2, wherein the glass sheet is a soda-lime-silica glass composition, and/or wherein at least one of the first mold part, the second mold part and the forming support is provided with heating means.
49. The method of claim 1 or 2, wherein at least one of the first and second mold parts comprises at least one of ceramic, aluminum, stainless steel, or iron.
50. The method of claim 49, wherein the iron is cast iron.
51. The method of claim 23, wherein the first and second mold parts each have a respective mold part cover, and wherein the mold part covers of the first and second mold parts are part of a single mold cover.
CN201880035219.1A 2017-06-01 2018-06-01 Method and apparatus for shaping glass sheets Active CN110691759B (en)

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JP7227927B2 (en) 2023-02-22
BR112019024731A2 (en) 2020-06-16

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